Flexible water-resistant sensor tag

Abstract

A method for configuring a sensor tag may include providing a flexible substrate layer comprising a thin film of thermoplastic polyurethane (TPU); depositing a sensor inlay on the flexible substrate layer; and applying a protective coating over the sensor inlay encapsulating the sensor inlay between the flexible substrate layer and the protective coating.

What is claimed is: 
     
       1. A method for configuring a sensor tag, comprising:
 providing a flexible substrate layer; 
 depositing a sensor inlay on the flexible substrate layer; and 
 applying a protective coating layer of thermoplastic polyurethane (TPU) over the sensor inlay; 
 wherein the applying further comprises leaving a TPU-free margin on the flexible substrate layer; 
 wherein the sensor inlay comprises an integrated circuit (IC) connected to an antenna. 
 
     
     
       2. The method of  claim 1 , wherein the protective coating layer comprises a colorless or colored TPU layer. 
     
     
       3. The method of  claim 1 , wherein the flexible substrate layer comprises a TPU layer, a fabric layer, a Polyurethane coated (PU) fabric layer, a nylon taffeta layer, a polyester taffeta layer, or a rubber layer. 
     
     
       4. The method of  claim 1 , wherein the flexible substrate layer comprises a fabric layer; and
 wherein the applying comprises encapsulating the sensor inlay and at least a portion of the fabric layer within the protective coating layer leaving the TPU-free margin. 
 
     
     
       5. The method of  claim 1 , wherein the TPU-free margin is around the flexible substrate layer. 
     
     
       6. The method of  claim 1 , wherein the sensor inlay comprises a radio-frequency identification (RFID) sensor. 
     
     
       7. The method of  claim 1 , wherein the sensor inlay is configured to provide flexibility so as to be repeatedly stretched or deformed without damaging functionality of the sensor inlay. 
     
     
       8. The method of  claim 1 , wherein the sensor inlay comprises an Electronic Article Surveillance (EAS) sensor or a radio-frequency identification (RFID) sensor. 
     
     
       9. The method of  claim 1 , wherein the TPU is configured to change states when an outside temperature source is applied. 
     
     
       10. The method of  claim 9 , wherein the sensor inlay wherein the sensor inlay adheres, cures, laminates or seals with the TPU in combination with the flexible substrate layer. 
     
     
       11. The method of  claim 1 , wherein the applying further comprises encapsulating the sensor inlay between the flexible substrate layer and the protective coating layer. 
     
     
       12. A sensor tag comprising:
 a flexible substrate layer; 
 a sensor inlay on the flexible substrate layer; and 
 a protective coating layer of thermoplastic polyurethane (TPU) over the sensor inlay; 
 wherein the protective coating layer includes a TPU-free margin on the flexible substrate layer; and 
 wherein the sensor inlay comprises an integrated circuit (IC) connected to an antenna. 
 
     
     
       13. The sensor tag of  claim 12 , wherein the antenna is formed using a conductive ink. 
     
     
       14. The sensor tag of  claim 13 , wherein the protective coating layer comprises a colorless or colored TPU layer. 
     
     
       15. The sensor tag of  claim 13 , wherein the flexible substrate layer comprises a TPU layer, a fabric layer, a Polyurethane coated (PU) fabric layer, a nylon taffeta layer, a polyester taffeta layer, or a rubber layer. 
     
     
       16. The sensor tag of  claim 13 , wherein the flexible substrate layer comprises a film of TPU. 
     
     
       17. The sensor tag of  claim 13 , wherein the protective coating layer encapsulates the sensor inlay and at least a portion of the flexible substrate layer leaving the TPU-free margin. 
     
     
       18. The sensor tag of  claim 13 , wherein the sensor inlay is configured to provide flexibility so as to be repeatedly stretched or deformed without damaging functionality of the sensor inlay. 
     
     
       19. The sensor tag of  claim 13 , wherein the sensor inlay comprises an Electronic Article Surveillance (EAS) sensor or a radio-frequency identification (RFID) sensor. 
     
     
       20. The sensor tag of  claim 13 , wherein the TPU is configured to change states when an outside temperature source is applied. 
     
     
       21. The method of  claim 1 , wherein the antenna is formed using a conductive ink. 
     
     
       22. The sensor tag of  claim 20 , wherein the sensor inlay wherein the sensor inlay adheres, cures, laminates or seals with the TPU in combination with the flexible substrate layer.